System and method for manufacturing optical fiber

ABSTRACT

A preform material including a starter tip to facilitate an initial fiber draw from the preform within a furnace, wherein the tip comprises a vacuum-sealed tip to receive a plastic grip which attached to an end of a preform.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/536,765 filed Jul. 25, 2017, the entirety of which is incorporated byreference.

BACKGROUND

Embodiments relate to manufacture of fiber optic cable and, moreparticularly to, a system and a method for manufacturing exotic opticalfiber in microgravity.

Traditionally, fiber optic draw towers are multiple meters tall, with atotal fiber path over 3 meters. This allows for fiber to completely coolbefore being coated, and makes control much easier. Further, the entiresystem is open, with human hands used at multiple stages formiscellaneous tasks. Most earth-based systems work by having the preform‘dropped’ after softening in the furnace.

Exotic optical fiber, such as the Fluoride-based fiber ZBLAN,theoretically provides 10-100 times better attenuation and significantlybroader transmission spectrum, compared to traditional silica fiber. Theterm “ZBLAN” is an abbreviation based its composition,ZrF₄—BaF₂—LaF₃—AlF₃—NaF. ZBLAN. ZBLAN may be used to enable highperformance fiber lasers, more capable medical equipment such as laserscalpels and endoscopes, supercontinuum light sources, more sensitivesensors for the aerospace and defense industries, and significantlyhigher bandwidth long-haul telecommunications connections. ZBLAN opticalfiber is currently produced on Earth and is sold in short lengths forutilization in fiber lasers, such as for medical, drilling, and imagegeneration, supercontinuum light sources, highly-nonlinear fibers,sensors, and other aerospace and defense applications. Currentlyapproximately 100 kilograms of ZBLAN optical fiber is produced yearly.Since such low quantities is produced, the full potential of thismaterial has not yet been realized.

Despite the theoretical performance of ZBLAN, due to extrinsicscattering and absorption, typical losses for terrestrially producedZBLAN fibers is worse than silica fiber. Furthermore, due to theselosses, terrestrially-produced ZBLAN is useless for telecommunicationsapplications.

Absorption losses are caused by impurities in the glass. Scatteringlosses are caused by microcrystals forming in fiber as it is pulled.There have been theoretical demonstrations showing that crystallizationis not present when fibers are formed in microgravity. Microgravitysuppresses ZBLAN crystallization, reducing scattering loses and leadingto significant performance improvements. In other words, the uniquecharacteristics of microgravity enable a fundamentally superior materialto be created. Crucially, due to the short duration of microgravity ontest flights, insufficient lengths of material were produced toquantitatively characterize these performance improvements. A kilometerof ZBLAN fiber weighs approximately 2 kilograms. One kilometer of ZBLANfiber can be produced from preforms, or solid glass rods, providingsignificant margin for operational costs, amortizing the costs of ZBLANproduction machinery and upmassing and downmassing the hardware andmaterial itself from a microgravity environment.

The standard procedure for pulling fiber from preforms is to beginheating the preform in the middle so that the weight of the preformcauses it to neck in the molten portion. The necking leaves a stillsolid portion of preform that is then pulled from the rest and a fiberforms between them. The drop is then cut from the fiber and that fiberis then pulled. This method is reliant on the force of gravity and wouldnot work in a microgravity environment.

Once pulled, optical fibers pulled are extremely vulnerable to damagefrom outside elements. To assist with this vulnerability, fibers arecoated post-pulling in polymer coatings to ensure the fibers longevityand functionality. This process uses a pool of melted polymer in whichthe fiber is run through as it is being pulled, creating a streamlinedprocess. For certain materials, such as silica, this process is ideal.However, with highly sensitive materials, such as ZBLAN, this processbecomes difficult.

This difficulty arises due to ZBLAN's high sensitivity to moisture,external contaminants, and relatively low pulling temperature whencompared to silica based fibers. ZBLAN fiber requires an ultracleanenvironment void of moisture and contaminants to be accurately produced.This makes post processing and streamlined coating processes difficultas the entire operation must conform to these meticulous environmentalconditions.

Currently, traditional terrestrial systems are heavily modified tooperate within a zero gravity or microgravity environment. Instead ofmodifying existing traditional terrestrial systems, a system andmanufacturing process specific to a microgravity environment is desired.Therefore, users and manufacturers of ZBLAN fiber would benefit from asystem and method which provides for a draw operation that is performedas autonomous as possible where the environment is controlled and aminiaturized draw tower, when compared to prior art, is utilized.

SUMMARY

Embodiments relate to a system and a method for manufacturing exoticoptical fiber in microgravity. The system comprises an autonomous feedsystem for transforming a preform into an optical fiber that is locatedwithin an enclosure in which environmental conditions are controlled.The autonomous feed system comprises a preform holder, endoscopicforceps, a finance, a plurality of pinch wheels which are autonomouslycontrolled to produce the optical fiber.

The method comprises removing moisture from the environment. The methodfurther comprises heating the preform until it is in a viscous state.The method also comprises applying tension to an end of the preform tocause a section of the preform to decrease in diameter forming a neck.The method further comprising extracting a small fiber from the neck andattaching an end of the small fiber to a spool. The method furthercomprises applying a polymer layer to the small fiber as further pulledfrom the neck.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description briefly stated above will be rendered byreference to specific embodiments thereof that are illustrated in theappended drawings. Understanding that these drawings depict only typicalembodiments and are not therefore to be considered to be limiting of itsscope, the embodiments will be described and explained with additionalspecificity and detail through the use of the accompanying drawings inwhich:

FIG. 1 illustrates a functional diagram of a system for manufacturingoptical fiber;

FIG. 2 illustrates another functional diagram of a system formanufacturing optical fiber;

FIG. 3 illustrates another function diagram of a system formanufacturing optical fiber;

FIGS. 4A-4D illustrate various views of an exemplary housing structurefor a system for manufacturing optical fiber;

FIGS. 5A-5B illustrate embodiments of a partially exposed view of anexemplary housing structure for a system for manufacturing opticalfiber;

FIG. 6 illustrates a perspective view of an exemplary system formanufacturing optical fiber;

FIG. 7 illustrates a perspective view of another exemplary system formanufacturing optical fiber;

FIG. 8 illustrates another exemplary system for manufacturing opticalfiber;

FIG. 9 illustrates another embodiment of the system;

FIG. 10 illustrates an exemplary preform holder fitted to an exemplaryfurnace for a system for manufacturing optical fiber;

FIG. 11 illustrates an embodiment of a micrometer;

FIGS. 12A-12C illustrate an embodiment of the furnace;

FIGS. 13A-13B illustrate further embodiments of the furnace;

FIG. 14 illustrates an embodiment of a preform holder;

FIG. 15 illustrates an exemplary redirection assembly for collectingfiber in a system for manufacturing optical fiber;

FIGS. 16A-16B illustrate an exemplary spooling mechanism for collectingfiber in a system for manufacturing optical fiber;

FIG. 17 illustrates an exemplary spooling mechanism for collecting fiberin a system for manufacturing optical fiber;

FIG. 18 illustrates an exemplary spooling mechanism with clamp forcollecting fiber in a system for manufacturing optical fiber;

FIG. 19 illustrates an exemplary perspective view of an exemplary systemfor manufacturing optical fiber with start/stop systems shown;

FIGS. 20A-20B illustrate an exemplary pinch wheel assembly for grippingfiber in a system for manufacturing optical fiber;

FIGS. 21A-21C illustrate an exemplary centering mechanism in a systemfor manufacturing optical fiber;

FIG. 22 illustrates an exemplary fiber cutting mechanism with wastecollector in a system for manufacturing optical fiber;

FIGS. 23A-23B illustrate an exemplary endoscope spool mechanism in asystem for manufacturing optical fiber;

FIG. 24 illustrates an exemplary gripping mechanism for initializingdraw from the preform in a system for manufacturing optical fiber;

FIG. 25 illustrates an exemplary perspective view of an exemplary systemfor manufacturing optical fiber with an exemplary gripping mechanismhighlighted;

FIGS. 26A-26B illustrate an exemplary environmental control unit in asystem for manufacturing optical fiber;

FIG. 27 illustrates an exemplary perspective view of an exemplary systemfor manufacturing optical fiber with an exemplary environmental controlunit highlighted;

FIG. 28 illustrates another embodiment of the system;

FIG. 29 illustrates exemplary method steps for removing componentmoisture in preparation for pre-coating a preform;

FIG. 30 illustrates exemplary method steps for assembling fixtures inpreparation for pre-coating a preform;

FIG. 31 illustrates exemplary method steps for preheating a preform inpreparation for pre-coating a preform;

FIG. 32 illustrates exemplary method steps for wrapping a preform in aprocess for pre-coating a preform;

FIG. 33 illustrates an exemplary preform holder for utilization in aprocess for pre-coating a preform;

FIG. 34 illustrates an exemplary heat gun application in a process forpre-coating a preform;

FIG. 35 illustrates an exemplary avionics bay with electronics boards ofa system for manufacturing optical fiber;

FIG. 36 illustrates exemplary method steps for data flow in a system formanufacturing optical fiber;

FIG. 37 illustrates an exemplary preform holder for a system formanufacturing optical fiber;

FIG. 38 illustrates an alternate exemplary preform holder for a systemfor manufacturing optical fiber;

FIG. 39 illustrates an alternate exemplary preform holder for a systemfor manufacturing optical fiber;

FIG. 40 illustrates an alternate exemplary preform holder for a systemfor manufacturing optical fiber;

FIG. 41 illustrates an alternate exemplary preform holder for a systemfor manufacturing optical fiber;

FIGS. 42A-42C illustrate an exemplary redirection assembly design for asystem for manufacturing optical fiber;

FIG. 43 illustrates exemplary path variations within a system formanufacturing optical fiber;

FIG. 44 illustrates exemplary assembled spools for a system formanufacturing optical fiber;

FIGS. 45A-45B illustrate an exemplary spooling assembly with redirectionassembly for a system for manufacturing optical fiber;

FIGS. 46A-46B illustrate an embodiment of assembled spools for a systemfor manufacturing optical fiber;

FIG. 47 illustrates a cross sectional view of an exemplary spool for asystem for manufacturing optical fiber;

FIGS. 48A-48C illustrate exemplary capstans with various gear designsfor a system for manufacturing optical fiber;

FIGS. 49A-49D illustrate an exemplary grabbing mechanism for a systemfor manufacturing optical fiber;

FIGS. 50A-50C illustrate an exemplary forceps control assembly for asystem for manufacturing optical fiber;

FIG. 51 illustrates exemplary steps for pulling fiber from a preform fora system for manufacturing optical fiber;

FIG. 52 illustrates an exemplary alignment mechanism for pulling fiberfrom a preform for a system for manufacturing optical fiber;

FIG. 53 is an embodiment of an integrated motor and capstan assembly forfiber spooling for a system for manufacturing optical fiber;

FIG. 54 illustrates exemplary embodiments of forceps designs for asystem for manufacturing optical fiber;

FIG. 55 illustrates exemplary embodiments of forceps control designs forinitiating fiber draw from a preform for a system for manufacturingoptical fiber; and

FIG. 56 shows a block diagram illustrating computing functionality of aprocessing system that may be used to implement an embodiment disclosedherein

DETAILED DESCRIPTION

Embodiments are described herein with reference to the attached figureswherein like reference numerals are used throughout the figures todesignate similar or equivalent elements. The figures are not drawn toscale and they are provided merely to illustrate aspects disclosedherein. Several disclosed aspects are described below with reference tonon-limiting example applications for illustration. It should beunderstood that numerous specific details, relationships, and methodsare set forth to provide a full understanding of the embodimentsdisclosed herein. One having ordinary skill in the relevant art,however, will readily recognize that the disclosed embodiments can bepracticed without one or more of the specific details or with othermethods. In other instances, well-known structures or operations are notshown in detail to avoid obscuring aspects disclosed herein. Theembodiments are not limited by the illustrated ordering of acts orevents, as some acts may occur in different orders and/or concurrentlywith other acts or events. Furthermore, not all illustrated acts orevents are required to implement a methodology in accordance with theembodiments.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope are approximations, the numerical values set forth inspecific non-limiting examples are reported as precisely as possible.Any numerical value, however, inherently contains certain errorsnecessarily resulting from the standard deviation found in theirrespective testing measurements. Moreover, all ranges disclosed hereinare to be understood to encompass any and all sub-ranges subsumedtherein. For example, a range of “less than 10” can include any and allsub-ranges between (and including) the minimum value of zero and themaximum value of 10, that is, any and all sub-ranges having a minimumvalue of equal to or greater than zero and a maximum value of equal toor less than 10, e.g., 1 to 4.

FIG. 1 illustrates a functional diagram of a system for manufacturingoptical fiber. A functional block diagram of system 100 formanufacturing optical fiber is illustrated. A series of primarymechanisms 140-165 centrally controlled by electronic mechanisms 105-120may be provided. The primary mechanisms may include, but are not limitedto an environmental control unit 140, an endoscope spool 145, a fiberspool 150, a redirection assembly 155, a furnace 160, and a preformholder 165. The control may be based on data received from at least onesensor, though as disclosed herein, a plurality of sensors may beprovided. As shown, a plurality of sensors 122-138 may be used. Suchsensors may include, but are not limited to an humidity sensor 122 thatis associated with the environment control unit 140, a temperaturesensor 124, a pressure sensor 126, a tension sensor 128 associated withthe fiber spool 150 and redirection assembly 155, an optical sensor 130also associated with the fiber spool 150 and redirection assembly 155,an optical sensor 132 that is associated with the redirection assembly155, a diameter sensor 134, a temperature sensor 136 and anaccelerometer 138.

In an embodiment, the system 100 may be primarily contained within ahousing 101, wherein the manufacturing of the optical fiber may occurwithin the housing 101.

Some electronic mechanisms, such as a power source 110, controller 115,and computer MIO 120, may be located externally. These electronicmechanisms may also be located internally, but locating them externallymay limit overheating.

The housing 101 may be hermetically sealed, wherein the internalenvironment may be controlled by the internal environmental control unit140, which may receive sensor data about ambient conditions, such as,but not limited to, from the humidity sensor 122. The environmentalcontrol unit 140 may provide for a stable and clean environment withinthe housing. In an embodiment, the environment may be monitored forambient conditions, such as, but not limited to, through use of thetemperature sensor 124 and the pressure sensor 126. Pressure andtemperature data may be collected for reference. In an embodiment,predefined levels of the pressure and temperature may trigger emergencyactions. As a non-limiting example, extremely high ambient temperaturesmay stop the furnace 160. As a non-limiting example, a loss of pressuremay stop the system 100 in which any components that move duringoperation may return to a locked or stationary position. The fiber spool150 may comprise a clamping mechanism 151 that may secure the fiber tothe fiber spool 150. In another embodiment, power to any component maybe disconnected. Starting and stopping the system 100 may be performedautonomously based on sensed data that is provided to a computingfunctionality of a processing system that may be used to implement anembodiment disclosed herein, as further illustrated in FIG. 56, tooperate the system 100.

A preform holder 165 may hold a plurality of preforms that may beinserted into a furnace 160, where the preform may be heated and fibermay be drawn from the heated preform. Preform loading and alignment maybe controlled in part by utilizing data from an accelerometer 138.

A temperature sensor 136 may monitor the temperature within the furnace160. In an embodiment, multiple temperature sensors 136, such as may beprovided as a sensor array, may allow for more precise control of thetemperature within the furnace 160. A temperature profile within thefurnace 160 may allow for a more effective draw of fiber from thepreform. A temperature probe 166 may be inserted into the furnace 160between preforms, wherein the preform holder 165 may comprise a reusabletemperature probe 166. The temperature probe 166 may comprise physicalproperties similar to or the same as a preform, wherein the temperatureprobe 166 may test the internal furnace conditions.

In an embodiment, an initial cutter 182 may precede the furnace 160,wherein the initial cutter 182 may detach pulled fiber from theremaining preform. A second cutter 174 may be located later in theprocess that may detach irregular or low quality fiber from thecollectible fiber. In an embodiment, the second cutter 174 may belocated proximate to a waste bin 172, which may collect the waste fiber.

In an embodiment, pinch wheels 180 may guide forceps, not shown, intothe furnace 160 to draw fiber from the preform. The pinch wheels 180 mayguide the fiber into a diameter sensor 134 through an initial iris 178that may center the fiber within the diameter sensor 134. In anembodiment, a secondary iris 176 may be located after the diametersensor 134 that may center the fiber as it exits the diameter sensor134. In an embodiment, the fiber may pass through an optical sensor 132that may monitor the quality of the fiber as it is drawn.

The diameter sensor 134 may be mounted under the furnace, and is used tomeasure the fiber diameter as it emerges from the furnace. This diametersensor is used in an active control loop to control the draw speed. Ifthe diameter is not correct, the draw speed is raised or lowered untilthe proper speed is reached to achieve nominal diameter.

As shown in FIG. 3, a cooling system can be integrated below thediameter sensor to rapidly cool the fiber before it is coated. In anembodiment, an air pump or a fan may be located perpendicular to thefiber, which cools the fiber by passing air over the fiber. Bladelessfans could also be used to channel air along the fiber length. Inanother embodiment to cool the fiber, it may also be possible to touchthe fiber with rolling pins, creating a conductive thermal pathway fromthe fiber.

The fiber may also be drawn through a redirection assembly 155, whichmay prepare the fiber for collection. The fiber may be pulled through aseries of sensors 130, 128, such as a second optical sensor 130 and atension sensor 128. The tension sensor 128 may allow the system torecognize if there is a break in the fiber and allow for control overspooling parameters by providing a sensed data that is provided to thecomputing functionality of a processing system as disclosed in FIG. 56.A fiber spool 150 may collect the fiber, wherein the draw speed 190 mayadjust based on sensor data that is provided to the computingfunctionality of a processing system. Non-limiting examples of thesensor include, but is not limited to, the diameter sensor 134, tensionsensor 128 or combination of multiple sensors. In an embodiment, anendoscope spool 145 may be located beyond the fiber spool 150.

FIG. 2 illustrates another functional diagram of a system formanufacturing optical fiber. As shown the preform holder 165, orcontainment device is disclosed. The preform holder 165 holds ontomultiple preforms as well as at least one temperature sensor 136. Itthen feeds preforms slowly into the furnace 160, providing the necessarymaterial for creating the fibers. The furnace 160 is used to soften theglass preforms. The temperature may be read from integrated sensors 136,and it is actively controlled, such as with an active controller 210, toinsure a stable thermal environment. Thus an active controller 210 isprovided. As disclosed above, a diameter sensor 134 or monitor isprovided. A fiber tractor 220 is provided to provide a pulling force todraw the fiber from the preform. A coating device 230, such as, but notlimited to a pressurized coating cup 231, is provided to apply a coatingto the generated fiber. The coating device 230 may further comprise anultraviolet (“UV”) curing lamp 232 to assist in solidifying the appliedcoating. Pump sensors 233 are also shown as being provided with thecoating device 230.

Also shown are several monitors devices, or sensors, includingtemperature sensors 136, relative humidity sensor 240, video camera 242,pump sensors 233, external force sensors 244 and diameter sensors 134.Also shown is a UV curling lamp 230 and a nitrogen storage tank 246.This take may or may not be within the housing 101. When not in thehousing 101, a feed line is provided through the housing 101.

As explained further herein, the drawing mechanism may comprise at leastone of a capstan, tractors, and/or spool. This mechanism provides thepulling force necessary to draw the fiber from the preform, as well aswind the created fiber into a compact vessel, such as, but not limitedto the spool, that can then be unwound back on Earth. These systems canbe split, allowing the fiber to travel longer distances inside the boxbefore being spooled. Further, several subsystems, identified asstart/stop subsystem, provide for drawing the fiber from a heatedpreform without the aid of gravity, as well as being used for stoppingthe drawing process in a controlled manner. The processor disclosedherein and active controllers provides for an autonomous start/stopsystem.

The tension and diameter monitors may be sensors used to take measuresof the tension in the line and the diameter of the created fiber,respectively. Humidity, temperature, and pressure sensors may be used todetect the parts per million (PPM) of water content, the temperature,and the pressure inside the controlled environment, respectfully.External Force Sensors, such as but not limited to at least oneaccelerometer, may be used inside the system to measure vibrations,which could affect fiber quality

As disclosed herein, the entire system may be held inside a controlledenvironment, defined by a housing. A high purity noble gas may be usedwithin the housing.

Communications (or command), control data handling (CD&H) is used torecord and transmit data from the process, as well as communicate withthe automated systems.

An electronics/power subsystems are used for conditioning power from thespace station, as well as controlling all the different subsystems.

A thermal subsystem comprises the subsystems necessary to cool theinterior and exterior of the system. Also, a structure and mechanismsprovide structure containing the environment and other subsystems, alongwith necessary mechanisms to make them function.

As a non-limiting example, the system disclosed herein launches fromEarth to the ISS in a form factor required by the Express Rack. Thisstructure is sealed to prevent any infiltration of humidity into thesystem, and filled with a dry environment. This environment may bemaintained with a gas pump circulating air through a HEPA filter, acarbon black filter, and molecular sieve, or other forms ofenvironmental control (such as pumping in fresh nitrogen from theexterior).

The process, in summary, revolves around taking a large diameter ZBLANpreform, heating that preform until it is in a viscous state, thenapplying tension to the end of this preform. This tension causes asection of the preform to decrease in diameter forming a “neck”. Fromthis neck, a small fiber can be pulled out and attached to a spool. Bychanging the spooling speed, the diameter of the fiber can becontrolled. Coating systems can then apply a polymer layer to the glass,allowing it to be bent without surface cracks breaking. Normally,gravity aids the process by automatically allowing the neck to form, asthe weight of the bottom of the preform causes the heated preform tonaturally draw down.

FIG. 3 illustrates another function diagram of a system formanufacturing optical fiber. As shown, a reform holder 165 is provided.Preform material is provided to a feeder position monitor that isprovided with a feeder speed device and the preform feeder 310. Thepreform material is provided to the furnace 160. A temperature sensor136 is provided at the furnace 160. In this embodiment a cooling device320 is shown, hence the optical fiber is pulled from the furnace and isfeed through the cooling device. A draw speed device 330 is provided ata capstan 330, through which the optical fiber is pulled. A tensionsensor 128 is shown to measure tension of the optical fiber afterpassing through the capstan 330. A spool speed device 340 is shown incommunication with the spool 150. A diameter sensor 134 is shown. As isalso visible, the draw speed device, feeder speed device and spool speeddevice are in communication with a diameter sensor. Though not shown, acontroller may be provided to use the data collected from the diametersensor to establish the speed of the feeder speed device, draw speeddevice and spool speed device. The ECU 140 is also shown along with ahumidity sensor and temperature sensor.

Referring now to FIGS. 4A-4D, various views of an exemplary housingstructure 101 for a system for manufacturing optical fiber isillustrated.

Referring now to FIG. 5A-5B, embodiments of a partially exposed view ofan exemplary housing structure 101 for a system for manufacturingoptical fiber is illustrated.

Referring now to FIG. 6, a side view of an exemplary housing structurefor the system for manufacturing optical fiber is illustrated. Thestructure 101 may comprise two pieces, a top welded shell 610 with adetachable left wall 620, and a bottom plate 630. The componentsdisclosed herein may be mated to the top shell 610 on an interior wall.In an embodiment, the components disclosed herein are separatedentirely. The pulling subsystems disclosed herein may be mounted to thebottom plate 630 or ease of assembly. The pulling assembly may belocated in a hermetically sealed, dry nitrogen environment.

Referring now to FIG. 7, a perspective view of an exemplary system 500for manufacturing optical fiber is illustrated. The system 500 maycomprise electronics 525 that may be located external to thehermetically sealed housing 101. In some aspects, the system 500 maycomprise an environmental control unit 530 that may maintain a stableand clean environment.

Referring now to FIG. 8, a perspective view of an exemplary system formanufacturing optical fiber is illustrated. The preform holder maycomprise a revolver design that carries a temperature sensor rod, aswell as several pre-coated preforms. These are moved into the furnacealong a linear axis. From the furnace, the fiber is led by endoscopicforceps through a diameter sensor, then through to the spooling system.Further, the environmental control unit and avionics bays are shown aswell, the former responsible for maintaining low humidity, the latterfor containing the electronics boards in a cooled environment. Theendoscopic forceps may be autonomously controlled by at least onecontroller disclosed herein where the controller receives data from atleast one sensor of the sensors disclosed herein to provide informationto allow for autonomous operations.

As further shown in FIG. 8, the preform holder 165 may be a solid staterevolver design that carries a temperature sensor rod 136, as well asseveral precoated preforms. These are moved into the furnace 160 along alinear axis. From the furnace 160, the fiber is led by endoscopicforceps through a diameter sensor 134, then through to the spoolingsystem 150. Further, the environmental control unit 140 and avionicsbays are shown as well, the former responsible for maintaining lowhumidity, the later for containing the electronics boards in a cooledenvironment.

Referring now to FIG. 9, a perspective view of an exemplary system formanufacturing optical fiber with pulling equipment shown is illustrated.In some aspects, the system may comprise a preform holder that may holda series of preforms and at least one temperature probe 136. In someaspects, the preform holder does not include a temperature probe. Thepreform holder may alternately insert a preform and temperature probeinto the furnace 160. Fiber may be drawn from a melted preform anddirected into a diameter sensor, such as a laser scanner, that maymonitor the diameter of the drawn fiber. Once the fiber reaches a targetdiameter, the subpar fiber may be disconnected and discarded into awaste collector, and the fiber within the diameter parameters may beguided onto a fiber redirection assembly 155, which may direct the fiberonto a spool.

Referring now to FIG. 10, an exemplary preform holder for a system formanufacturing optical fiber is illustrated. In some aspects, the preformholder may comprise a revolver mounted on a high accuracy stepper motor,which may be mounted to a linear axis. In some embodiments, the preformholder may comprise a temperature probe that may be inserted into thefurnace between preforms, which may ensure that the temperature profilewithin the furnace is constant.

Referring now to FIG. 11, an exemplary micrometer 1201 for a system formanufacturing optical fiber is illustrated. In some aspects, a laserscanner, such as a high accuracy Aeroel XLS13XY/480, may measure bothdiameter and concentricity. In some implementations, such as where thesystem may be subjected to heavy vibrations, the micrometer may besecured to the housing to limit movement.

The furnace 160 is used to create the heated environment for thepreform, or preform material. This environment will decrease theviscosity of the preform in certain sections, allowing the preform to bedrawn into fiber. The furnace 160 may be cylindrical, with an opening atthe top, or a first side, of the furnace 160 allowing for the preform tobe inserted and an opening at the bottom, or a second side, allowing forthe generated fiber to be pulled towards the spooling system.

The furnace 160 could have several possible designs. The currentbaseline is a stainless steel cylindrical element with insertedcartridge heaters, which are controlled using an active PID loop. In anembodiment, a furnace 160 may include a hot wire or pipe that hasdifferent modes of heating through different amounts of wire turns in aset volume, or by utilizing radiative methods with extremely hotlocalized elements.

Further, this furnace can have an installed system built in so thatambient gas can be drawn inside, heated, and forced into the furnace tocreate a temperature profile like one generated on Earth. The air pump,fans, and parameters necessary for this are being investigated.

Referring now to FIGS. 12A-12C, perspective views of an exemplaryfurnace for a system for manufacturing optical fiber are illustrated. Insome aspects, a furnace mount 1220 may comprise aluminum. In someembodiments, the heating element 1230 may be positioned between twographite insulative pads 1235, 1236, which may keep the heating elementin place while not conducting heat. In some implementations, the iris1240 may be mounted to the furnace.

Referring now to FIG. 13A, an exterior view of an exemplary furnace fora system for manufacturing optical fiber is illustrated.

Referring now to FIG. 13B, an interior view of an exemplary furnace 160for a system for manufacturing optical fiber is illustrated. The heatedelement 1230 is shown. As a non-limiting example, the heated element maybe made of brass or another metal or material, such as, but not limitedto a ceramic material. A tube is shown, such as, but not limited to aquartz tube 1320, to remove emissions from the heated element. Analignment pin and screws 1310 are also visible. A housing 1330 is shown.As a no-limiting example, the housing 1330 may be a stainless steeljacket.

The furnace 160 may be used to heat the preform so that fiber may bepulled from it. As a non-limiting example, the furnace 160 may comprisea stainless steel element heated by 4 cartridge heaters and, as anon-limiting embodiment, may use a plurality, such as, but not limitedto up to 4, resistance temperature detectors (RTDs) to useproportional-integral-derivative (PID) control of the temperature. Thiselement may be surrounded by a stainless steel jacket, with air or gas,insulation between the heated element and the outer jacket. The heatedelement is secured in the jacket using either insulative pads or screws.The jacket is then secured into a metal mount, which is bolted to thebottom plate of the structure.

As is illustrated herein, the furnace 160 could have a plurality ofdesigns. In an embodiment, a stainless steel cylindrical element withinserted cartridge heaters is provided, which are controlled using anactive PID loop. A quartz tube 1320 could also be included to ensurethat emissions from the steel element do not affect the heated preform.Another non-limiting embodiment of the furnace 160 may include a hotwire or pipe that has different modes of heating through differentamounts of wire turns in a set volume, or by utilizing radiative methodswith extremely hot localized elements.

In some aspects, the furnace 160 may comprise a transparent material,wherein at least a portion of the interior of the furnace may bevisible. A visible interior may allow for a precise initial fiber drawfrom the preform at a hotspot, where the preform is at a melting pointor in molten form. In some embodiments, such as in microgravity, forcepsmay be inserted or touched to the surface of the molten form toinitialize the fiber draw. Utilizing a hotspot to initialize the fiberdraw may reduce loss of fiber that may occur through other draw methods.As a non-limiting example, where the preform may comprise a disposabletip, any portion attached to that tip may be wasted. In some aspects,the internal topography of the furnace 160 may be varied, wherein thevariation may allow for predefined temperature profiles within thefurnace.

In an implementation, the hotspot may be determined by directing a lightsource through the preform and measuring the light as it exits thepreform. A pattern may be added to the bottom of the preform, whereinthe pattern may change as the preform melts. As the pattern changes, oneor both the shadow or the light may be distorted. The pattern maycomprise an impression on the surface of the preform or may be coatedwith a pattern, such as with polytetrafluoroethylene (PTFE).

In an embodiment, forceps may draw fiber from the preform at apredefined location within the furnace. As a non-limiting example, oneor both a temperature probe or temperature sensors may indicate theinternal temperature profile of the furnace. A target pull locationwithin the furnace may be based on the temperature profile, preformmaterial properties, and speed of preform insertion. The initial fiberdraw may draw the fiber from the furnace into the micrometer, which maymeasure the diameter of the fiber. The speed of insertion may beadjusted throughout the draw process to reach and maintain the targetfiber diameter.

In some aspects, the furnace may comprise a heating core and aninsulator portion, which may limit the heating of the ambientenvironment. The insulator portion may comprise a housing and aninsulating material or mechanism. As an example, the insulator portionmay comprise circulating air. Further, this furnace can have aninstalled system built in so that ambient gas can be drawn inside,heated, and forced into the furnace to create a temperature profile likeone generated on Earth. The air pump, fans, and parameters necessary forthis are being investigated.

Over time, the interior portion of the heating core may corrode, fibermay build up on the surface, or general damage may occur. In someaspects, where the system may be accessible, the heating core may bereplaceable. A replaceable core may allow for extended use of the systemwithout requiring extensive repairs. In some embodiments, the heatingcore may be replaced through automation or manually. The replaceableheating cores may ship with the system, wherein the heating cores may bereplaced without requiring a separate launch. The replaceable heatingcores may be launched in batches as needed or before needed, which mayallow for continuous functionality of the system.

The temperature range of the furnace may be different for differenttypes of preforms, such as different glass types or coatings. In someaspects, the temperature range may be adjustable. In some aspects, afurnace may be customized to a particular glass type, such as ZBLAN,which has a lower melting point than other standard optical fibermaterials. In some embodiments, the heating core or the furnace may beinterchangeable, which may allow for a change in glass type or preformsize without requiring a completely new system.

Referring now to FIG. 14, an exemplary preform holder fitted to anexemplary furnace for a system for manufacturing optical fiber isillustrated. In some aspects, pads (e.g., foam pads, rubber pads) may beintegrated into the side of the furnace to contain the preforms duringlaunch. The preforms may be contained in these pads to prevent damagefrom vibration during launch

Referring now to FIG. 15, an exemplary redirection assembly forcollecting fiber in a system for manufacturing optical fiber isillustrated. In some aspects, the redirection assembly may be a compactversion of full wheels, wherein both redirectors may move independently.The one towards the spool may translate the fiber during spooling andmay integrate a full wheel and tension sensor. The one towards thefurnace may move to allow for waste disposal

Referring now to FIGS. 16A-16B, an exemplary spooling mechanism forcollecting fiber in a system for manufacturing optical fiber areillustrated. FIG. 16A shows the spool component without an outercover.In some embodiments, the spool 150 may comprise an embedded DC motor andgearbox 128. A passive clamp may be used to grip fiber down to thespool. For example, RPM may be less than 50 at all times to reducechance of breaking the fiber.

Referring now to FIG. 17, an exemplary spooling mechanism for collectingfiber in a system for manufacturing optical fiber is illustrated.

Referring now to FIG. 18, an exemplary spooling mechanism with clamp forcollecting fiber in a system for manufacturing optical fiber isillustrated. The spool 150 may use a clamp, springs, and a small magnetto initialize a clamp on the fiber. A servo 1810 may move the magnetdown, make contact on the clamp, and pulling up. The fiber may be drawnunder the clamp. The servo may pull up farther, breaking the connectionbetween the magnet and clamp. The spring may bring the clamp down ontothe fiber and pin it.

Referring now to FIG. 19, an exemplary a perspective view of anexemplary system for manufacturing optical fiber with start/stop systemsshown is illustrated.

The start/stop subsystem 1901 is a general name for starting the pullingprocess, as well as ending it. The subsystem 1901 interfaces with aspooling subsystems extensively. The system 1901 begins the neckingprocess of the preform as disclosed herein, either by poking the moltenend of it, or by pulling a large section of the bottom. Once the neck isformed, the waste can be disposed of, and a subsystem used to draw thefiber through the entire system, eventually attaching the fiber to aspool. There can be several different tractors, cutting assemblies, andirises used for this process.

A grabber mechanism is provided which inserts into an attached mount onthe preform. The grabber inserts into the preform once the preform isinserted into the hot spot, applying a constant force to simulate 1G ofgravity or the force of Earth's gravity. The grabber may then pull thebottom chunk of material and mount back, then cut the residual off themain fiber strand. Irises and pinch wheels 180 then may be provided toclose around the fiber strand, inserting the fiber into a waste binuntil it is the proper size to go through the rest of the system.Endoscopic forceps extend from behind the spool, through a clamp andtwo-redirection assemblies, though a single redirection assembly may beused, and grabs the end of a cut fiber that has been pulled from thepreform. The forceps then draw this fiber back through the system and tothe spool, where the fiber is attached. Drawing of the fiber can thencommence.

In order to stop pulling, the preform feeding is stopped, and either thefiber is cut or allowed to break at the neck. The spool continues topull this loose fiber through the system, where it is finally secured tospool for safe keeping until reentry, bringing the fiber back to Earthfor use.

Referring now to FIGS. 20A-20B, a perspective view of an exemplarysystem for manufacturing optical fiber with start/stop systems shown isillustrated. A pinch wheel assembly 180 may be used to grip fiber andget it to desired diameter before drawing through system. This assemblymay be removed based on testing, depending on fiber sensitivity tobending, as well as size of fiber when drawn out of furnace. A cover2010, as shown in FIG. 20B, may also be provided.

Referring now to FIGS. 21A-21C, an exemplary centering mechanism 2101 ina system for manufacturing optical fiber is illustrated. An iris 2110may be used to center the fiber for the start/stop process. In someaspects, the iris 2110 may comprise a servo and machined parts 2120 thatmay fit into each other as the fiber is centered. A covering 2130, asshown in FIGS. 21B-21C, may be provided to enclose the componentsassociated with the iris.

Referring now to FIG. 22, an exemplary fiber cutting mechanism 2201 withwaste collector 2210 in a system for manufacturing optical fiber isillustrated. In some aspects, a wire cutter may be heated nichrome wire,which may cut through the fiber. The cutting mechanism 2201 may be usedto end the process, as well as during certain parts of the startprocess. The waste collector 2210 may be used to keep waste fiber andused to contain large preform ‘drops.’ A fan may be used to ensure allwaste is sucked to the bottom of the container.

Referring now to FIGS. 23A-23B, an exemplary endoscope spool mechanismin a system for manufacturing optical fiber is illustrated. Anendoscopic spool may hold and control the opening and closing of theforceps. In some aspects, the endoscopic spool 2301 may be locatedbehind the spooling mechanism, and the endoscopic spool 2301 may feedthe forceps through the system, where it may release the fiber onto thespooling mechanism.

Referring now to FIG. 24, an exemplary gripping mechanism 2501 forinitializing draw from the preform in a system for manufacturing opticalfiber is illustrated. A gripper 2510 may be used to insert intopreattached grips on the preform. The gripper 2510 may also be referredto as a force sensor as it creates 1G of gravity to initiate drawing theoptical fiber form the preform material. The gripper mechanism maycontain a small load cell to ensure force remains in acceptabletolerance. In some aspects, the gripper may pierce the tip of a viscouspreform, wherein pulling the piercing may initiate a fiber draw.

Referring now to FIG. 25, a perspective view of an exemplary system formanufacturing optical fiber with an exemplary gripping mechanism 2501highlighted is illustrated. The gripper 2510 can be moved out of the wayto allow for the fiber redirection assembly to be moved into place,which may also allow for residual globs to be added to the wastecollector.

The system described herein is sealed to prevent any infiltration ofhumidity and filled with a dry environment. This environment could bemaintained with a gas pump circulating air through a high efficiencyparticulate air (HEPA) filter, a carbon black filter, and molecularsieve, or other forms of environmental control, such as pumping in freshnitrogen from the exterior.

In some implementations, the system may comprise an environment controlunit (ECU) 140. The ECU 140 is used to maintain the environment when thepulling operation is not occurring. The ECU 140 utilizes filters toeliminate particles, volatiles, and humidity from the inert gasatmosphere inside the environment. In an embodiment, the ECU 140 may usea fan to suck air through a filter, such as but no limited to a HEPAfilter, and activated charcoal. This air is then pushed through amolecular sieve. The molecular sieve may have baffles to create a longpath for the flow through the sieve. Thus, the ambient environment canbe completely clean including filtering out of water.

The ECU 140 may be periodically active, such as during operation of thefurnace. In some embodiments, such as where materials may be restocked,the system may be continuously operating. The ECU 140 may continuouslyoperate, may operate periodically, or based on monitored conditions.

In some aspects, an ECU 140 may maintain the environment according topredefined condition parameters. An ECU 140 may comprise a filter and afan that may draw air into the filter. The filter may comprise one ormore a HEPA filter, charcoal, specialized ceramic, or a molecular sieve,as non-limiting examples. In some aspects, surface area may be increasedthrough use of baffles or tubing. Tubing may allow the ECU 140 to beadapted into non-standard shapes and fit between the components in thesystem. The ECU 140 may comprise passive and active components. Forexample, the fan may draw air through the ECU 140 when the system isactive, such as when the furnace is on or fiber is being spooled. TheECU 140 may passively filter the air when the system is not in operationand a separate circulation device, such as a fan, may be collectingdebris from a prior fiber draw.

In some embodiments, the ECU 140 may be replaceable, such as where thesystem is accessible. Where the system may be opened and accessed, theECU 140 may be periodically replaced manually or through automation. Insome aspects, the environment may be large enough to include anautomation system that may replace consumable and damaged components.The ECU 140 may not be activated until the system is in use or at leastuntil the system is sealed. For example, the ECU 140 may periodicallyrun while the system is in storage to maintain the environment withinthe predefined parameters.

In some aspects, the ECU 140 may be engaged during the assembly process,wherein the ECU 140 may initiate the purging of the system, as thehousing is hermetically sealed. The system may be over-pressured andunder-pressured to effectively purge the environment. One or more thesystem or its components, such as, but not limited to, the filter,molecular sieve, pump or fan and an inner or internal surface of the ECU140 housing, may be baked until they are effectively outgassed. Theentire system may be flushed with nitrogen gas, helium, or other gas tocontrol the oxygen levels. In some aspects, where the system is flushedwith an inert gas, at least a portion of the assembly may occur withinan inert gas environment. In some aspects, the components or preformsmay be pretreated before assembly, such as with methanol.

In some embodiments, an ECU 140 may comprise a cooling mechanism thatmay supplement general airflow mechanisms in the case of emergencies.For example, in the event of a failure, there may be a need to quicklylower temp to prevent fiber from sticking to walls of the furnace orother parts within the box. If the furnace overheats, a coolingmechanism may reduce damage from furnace failure.

More particularly, referring now to FIGS. 26A-26B, an exemplaryenvironmental control unit in a system for manufacturing optical fiberis illustrated. In some aspects, an ECU 140 may comprise a compactrectangular package 2701, or housing, but with the incorporation ofbaffles, can still give a long residence time of the air with the sieve2720. It can be used with either a high throughput fan, or a higherpressure pump. It incorporates both a charcoal filter 2710 and HEPAfilter 2712. Note that these filters will be the first to touch theflow, so that only clean, slow, and uniform airflow touches themolecular sieve 2720. Moreover, these filters can clean the interior ofanything outgassed during a pull. In some embodiments, the ECU may haveintegrated humidity sensors. The ECU 140 may communicate with sensorslocated throughout the system, such as sensors for temperature,pressure, or contamination.

Thus, as shown, activated charcoal filters 2710 (or carbon blackfilters) and HEPA filters 2712 are located in order to cleanse the airfrom any contaminants. Then, a molecular sieve 2720 is contained in aseries of meshes and baffles, which dehumidifies the air or dry the airto the single PPM range. This subsystem is used both before unitoperation, to dry any residual humidity from the environment during abake out, and between operations to filter any outgassed air.

Other configurations than the box configuration can be used, such as,but not limited to a cylindrical configurations and a tubeconfiguration. Thus, form factor of the unit to change based on what isneeded for the flight system.

The molecular sieve 2720 may be contained in a series of meshes andbaffles, which dehumidifies the air. The molecular sieve 2720 may drythe air to the single PPM range. This subsystem may be used both beforeunit operation, to dry any residual humidity from the environment duringa bake out, and between operations to filter any outgassed air.Configurations other than the box configuration may be used, including,for example, cylindrical configurations tube shaped systems. These allowthe form factor of the unit to change based on what is needed for theflight system.

In some implementations, scrubbing/cleaning a gas environment ofmoisture may enhance the manufacturability of fiber optic materials in acontained environment. In some aspects, drawing (pulling)/pushing theenvironmental fluid through a filter membrane then through a molecularsieve then back to the environment may be autonomous and inherent to theclosed system. By using a closed system, it ensures environmentalquality of the fluid, thus limiting the chance for imperfections/defectsin the manufacture in the fiber optic material. The system operates bysensing the humidity in the environment and then turning on when itbecomes greater than the set desired level. The manufacturingenvironment may be isolated from external environmental elements.

Referring now to FIG. 27, a perspective view of an exemplary system formanufacturing optical fiber with an exemplary environmental control unithighlighted is illustrated.

FIG. 28 is another embodiment of the system. As shown, the systemcomprises the ECU 140, the spool, a redirection assembly, a waste waterdisposal container. A cutting device, a micrometer, pinch wheels, thefurnace, the preform holder and the endoscopic forceps.

A method provides for scrubbing/cleaning a gas environment of moisture,water, to enhance the manufacturability of fiber optic materials in acontained environment. This method utilizes a method of drawing(pulling)/pushing the environmental fluid through a filter membrane thenthrough a molecular sieve then back to the environment. This method isautonomous and inherent to the closed system. By using a closed system,it ensures environmental quality of the fluid, thus limiting the chancefor imperfections/defects in the manufacture in the fiber opticmaterial. They system operates by sensing the humidity in theenvironment and then turning on when it becomes greater than the setdesired level. The manufacturing environment will be isolated fromexternal environmental elements.

Thus, the method comprises sensing humidity in the environment, where anoptical fiber is being manufactured, with a sensor. The method furthercomprises relaying the sensed data to a controller. The method alsocomprises drawing environmental fluid through a filter membrane thenthrough a molecular sieve then back to the environment with at least oneof a fan and a pump based on the sensed data to control environmentalconditions where the optical fiber is being manufactured as controlledby the controller.

The method may also comprise comprising accelerating flow reduction to alower temperature with a cooling mechanism. Also, the method maycomprise outgassing at least one of the filter, the molecular sieve, atleast one of the pump and the fan and an internal surface of the housingwith a heater.

Referring now to FIG. 29, exemplary method steps for removing componentmoisture in preparation for pre-coating a preform are illustrated. Themethod 2900 may comprise the components that may be cleaned of all oilsand contaminates using the proper solvent/cleaner for the material, at2910. The components may be placed in the vacuum chamber of the gloveboxand open the vacuum valve, at 2920. As a non-limiting example, thecomponents may be left in the chamber for 30 minutes to an hour, at2930. The chamber may be filled with clean dry nitrogen at 2930. Thesteps in the glovebox may be repeated, at step 2950, and the componentsmay be transferred into the glove box with the environmental atmospherebeing circulated through a molecular sieve, at step 2960.

Referring now to FIG. 30, exemplary method steps for assembling fixturesin preparation for pre-coating a preform are illustrated. The method3000 comprises the components that may be vacuumed, at step 3010, andthen assembled, at step 3020. The preform may be gripped, at step 3030,so that approximately 0.5 inches (8 mm), plus or minus a quarter of aninch, is being gripped by a collet. The preform may be placed in thecenter of the assembly, at step 3040, so that if spun the preformremains as concentric as possible. Tightening may be performed, at 3050,so that the collet grips the preform, wherein not to over tightenlimitations are provided. In an embodiment, hand tight is fine. Theconcentricity of the preform may be verified, at step 3060, by turningthe assembly and observing the preform.

Referring now to FIG. 31, exemplary method steps for preheating apreform in preparation for pre-coating a preform are illustrated. Thewater content of the glove box may be confirmed for <1 PPM watercontent, at step 3110. The motor, which may be a stepper motor, such asbut not limited to a NEMA 17 motor, may be mounted, at step 3120,approximately 8-10 inches, plus or minus one inch, vertically in an areaa heat gun freely may be freely manually manipulated. Though a heat gunis disclosed, other heat producing or generating sources may be used.Therefore, a heat gun is non-limiting. The preform holder may be slidwith the ZBLAN preform onto the shaft of the motor, at step 3130, andturn the motor on to a desired speed, such as but not limited to 30 RPM.A heat gun may be provided and set at a desired temperature, at step3140, such as, but not limited to approximately 300° F. (149° C.), plusor minus five degrees, at a low fan setting, which may be placed on thefloor of the glovebox so that it is not blowing on or near the preformand up. The glovebox atmosphere may reach a steady state, at 3150.During this time, pressure and moisture content in the glovebox willrise and may be monitored closely, relieving pressure when applicable.The glovebox may remain like this until the moisture level is less than1 PPM water.

The heat gun may start a distance away from the preform traversing backand forth at approximately 1 inch (25 mm), plus or minus half an inchfor approximately 2 minutes, plus or minus a minute, at step 3160,wherein a non-limiting example of distance may be approximately 8inches, plus or minus two inches. The heat gun may move closer, at step3170, such as but not limited to approximately one inch, to the preformrepeating the above process until a given distance away, such as, butnot limited to approximately three inches (76 mm), plus or minus oneinch, from the preform is achieved. The preform is removed from theholder assembly, at step 3180.

Referring now to FIG. 32 exemplary method steps for wrapping a preformin a process for pre-coating a preform are illustrated. During thisprocess, 3200, the PPM of water moisture level inside the glove box maybe between approximately 0-1.5 PPM, plus or minus 0.25 PPM. If it raisesabove this level, the process may be shut down until it falls below 1PPM before restarting. The heat gun may reach the appropriatetemperature, at step 3210, keeping the fan speed at the lowest setting.A Type K thermocouple or equivalent may be used to test the temperatureof the heat gun approximately 2.5 inches (63 mm), plus or minus 0.5inches, from the nozzle. Verify it is within ±10° of the desiredtemperature. If the temperature is not within the appropriate rangeadjust the heat gun's temperature accordingly until the propertemperature is achieved.

The preform may be removed from the holder assembly, at step 3215. Thepreform may be inserted into a piece of shrink tubing ˜1.5″ (38 mm)longer than the preform, at step 3220, so there is an equal amount oftubing on either end. The wrapped preform assembly may be heldapproximately 3 inches (76 mm), plus or minus one inch, above the heatgun, wherein the overhanging tubing may slightly shrink, at step 3225.The excess tubing may be removed from the shrunk end, at step 3230. Thenewly cut end may be placed in the holder, at step 3235, and the holdermay be placed on the motor, at step 3240.

The heat gun may be aimed at the free end of the wrapped preform at a45°-60° angle from the rotational axis (see FIG. 34). The heat gun maybe moved back and forth over a 0.5″ (13 mm) length until the tubing hasshrunk which for PTFE tubing will turn clear then shrink, at step 3245.

The preform may cool, at step 3250, to less than approximately 200° F.(93° C.), plus or minus ten degrees and then may be removed from theassembly and flipped around, at step 3255, where the other side may beshrink-wrapped. The preform may be examined for bubbles, at step 3260,if any appear hold the heat gun over that area moving back and forth asbefore. Once completed, the preform may be cooled to ambient, at step3265, and the excess tubing may be cut from the wrapped preform, at step3270.

Referring now to FIG. 33, an exemplary preform holder for utilization ina process for pre-coating a preform is illustrated. A preform materialextends from the preform holder 3301. A clamp 3310 is provided to holdthe preform material. Also shown is a guide rod 3320 and engagementthreads 3330 which are used to secure the clamp 3310.

Referring now to FIG. 34, an exemplary heat gun application in a processfor pre-coating a preform heat gun is illustrated. As shown a heat gun3401, is applying heat to a preform, a preform material, or a materialrod. A coating 3410 is shown as being around the preform material.

Referring now to FIG. 35, an exemplary avionics bay with electronicsboards of a system for manufacturing optical fiber is illustrated.

Referring now to FIG. 36, exemplary method steps for data flow in asystem for manufacturing optical fiber is illustrated. The fiber opticproduction facility is referred to as “MISFO.” In some aspects, aportion of the steps may occur manually prior to launch or may beomitted. Software may perform tasks throughout the process, andinstallation may occur manually. Collection of the fiber and data afterretrieval may occur manually and through use of software.

Referring now to FIG. 37, an exemplary preform holder for a system formanufacturing optical fiber is illustrated. The preform holder 165 mayinclude a rotatable revolver piece 3701 with preforms secured usingstainless steel clamps 3710. The revolver may be turned using a highlyaccurate stepper motor, and translated using a linear rail with attachedstepper. In some aspects, homing sensors may be used to ensure knowledgeof position and autonomous operation.

Once a preform is aligned with the top of the furnace 160, it may bemoved through the furnace 160 using the rail 3720. It may be fed at aset rate, feeding new material into the hot spot of the furnace so thatnew fiber can be pulled.

Thus, it may rotate a solid revolver piece, with preforms secured usingstainless steel clamps. The revolver is turned using a highly accuratestepper motor, and translated using a linear rail with attached stepper.Homing sensors may be used to ensure knowledge of position andautonomous operation. Once a preform is aligned with the top of thefurnace, it is moved through the furnace using the rail. It is fed at aset rate, feeding new material into the hot spot of the furnace so thatnew fiber can be pulled.

Referring now to FIG. 38, another exemplary preform holder for a systemfor manufacturing optical fiber is illustrated. In some aspects, thepreform may comprise a trident 3810, which may hold multiplecantilevered preforms in a linear stepper on a traversal. The preformsmay be gripped in chucks mounted to a backboard 3820. The backboard 3820may be translated forward to feed the current preform into the furnace160. Once the preform feed is complete, the residual preform isretracted and the next preform translated into an aligned position withthe furnace 160. In another embodiment, the linear stepper is mounted ona traversal. Two actuators may be needed.

Referring now to FIG. 39, an alternate exemplary preform holder 165 fora system for manufacturing optical fiber is illustrated, wherein thepreform holder comprises a solid-state revolver 3701. With a linear railand a rotary actuator 3720, the preform holder 165 may support multiplepreforms. Similarly to the trident example, the preform holder is notdeformed or changed, but remains “solid-state.” Here, instead of atrident design, the preforms may be mounted to a revolver. The systemmay translate forward to feed a preform into the furnace. Once thepreform feed is completed the residual is retracted, and a new preformmoved into place by revolving the entire backboard.

Referring now to FIG. 40, another embodiment of a preform holder for asystem for manufacturing optical fiber is illustrated. Using a guiderail 3720 to the furnace 160, a linear actuator, a rotary actuator, anda ‘screw or bolt’ actuator, may increase the amount of preforms used.Here, the preforms may be mounted to a revolver which can rotate.However, the preforms may be removed from their mounts, and translatedseparately using the linear axis. This may free up space on the revolver3701 for increasing the number of preforms.

Referring now to FIG. 41, another embodiment of a preform holder for asystem for manufacturing optical fiber is illustrated. Using a guiderail 3720 to the furnace 160, 2 linear actuators, and a ‘screw or bolt’actuator may increase the amount of preforms used. Similar to therevolver embodiments, except instead of a revolver driven by stepper andthe preforms being removed from the revolver with a translation device,the preforms are fed in using a ‘clip’-like system, where preforms arestored on a rail, and then translated using a linear actuator or springinto a feed position. Once they are in this position, the preforms canbe moved into the furnace using a linear axis. This concept allows forthe most efficient preform packing, but is complex.

The preform containment and feed system may be provided with differentconcepts for holding multiple preforms. One may use a solid-staterevolver to hold the preforms in a circular configuration, while othersmay utilize different magazine designs that use springs or motors tomove preforms into position.

In one embodiment, the preforms is mounted on two linear rails in atrident position. The preforms are gripped in chucks mounted to abackboard. The backboard is translated forward to feed the currentpreform into the furnace. Once the preform feed is complete, theresidual preform is retracted and the next preform translated into analigned position with the furnace.

Similar to the trident example, in that the preform holder is notdeformed or changed, but remains ‘solid-state’, instead of a tridentdesign, the preform may be mounted to a revolver. The system cantranslate forward to feed a preform into the furnace. Once the preformfeed is completed the residual is retracted, and a new preform movedinto place by revolving the entire backboard. This is both less complexthan the next two methods listed and space saving over the tridentexample.

In another embodiment, the preforms are mounted to a revolver 3701 whichcan rotate. However, the preforms can be removed from their mounts, andtranslated separately using the linear axis. This is similar to a bulletbeing fed to a chamber from a revolving magazine. This frees up space onthe revolver for increasing the number of preforms.

Similar to the embodiment immediately above, instead of a revolverdriven by stepper and the preforms being removed from the revolver witha translation device, the preforms are fed in using a ‘clip’ likesystem, where preforms are stored on a rail, and then translated using alinear actuator or spring into a feed position. Once they are in thisposition, that can be moved into the furnace using a linear axis. Thisconcept allows for the most efficient preform packing, but is complex.

In the creation of an autonomous fiber pulling device the ability toredirect delicate fibers is critical. When the assembly needs to shrinkdue to limited area for a system, the pulley wheel takes up considerablevolume. To save volume several small pulleys can be arranged so thattheir surfaces are tangent to the surface of the larger pulley. Thefiber can then take the direction change resting on several pulleys thattake up considerably less volume than the equivalent single large pully.Surrounding the pulleys is a guide path that allows an endoscope likemechanism to be pushed through the pulley assembly and then retractedwith a fiber attached so that the fiber only contacts the metal bearingsand no other surface.

Referring now to FIGS. 42A-42C, an exemplary redirection assembly designfor a system for manufacturing optical fiber is illustrated. It isarranged onto rails, enabling them to be moved, both to change the fiberfeed path onto the spool, and to enable it to be moved into positiononce the start/stop process is initiated.

In the creation of an autonomous fiber pulling device, redirection ofdelicate fibers is essential. Surrounding the pulleys is a guide paththat allows an endoscope-like mechanism to be pushed through the pulleyassembly and then retracted with a fiber attached so that the fiber onlycontacts the metal bearings and no other surface.

Referring now to FIG. 42B, an exemplary cutaway displaying the interiorof the fiber redirection assembly is shown. Metal bearings may be usedto redirect the fiber without the need for a large wheel or pulley.

Referring now to FIG. 42C, an exemplary portion of the fiber redirectionsystem is shown. Note that all edges can be rounded and funnels added toinsure the fiber is center.

Referring now to FIG. 43, exemplary path variations within a system formanufacturing optical fiber are illustrated. In some aspects, these maybe lined up at slight angles, so that the fiber path could be increasedto larger and larger lengths if required. This distance allows the fibertime to cool, and allows the spool to mount in different configurations.The left shows using a wheel, the center using a fiber redirectionassembly, and the right showing the ability to customize the path asneeded using either method. Note that many of these can be lined up atslight angles, so that the fiber path could be increased to larger andlarger lengths if required. The allows the fiber time to cool, or allowsthe spool to mounted in different configurations, as shown below.

Referring now to FIG. 44, an exemplary spooling assembly for a systemfor manufacturing optical fiber is illustrated. A large spool 4401responsible for housing as well as opening and closing the endoscopicforceps 4410 is shown on the far left. A stepper motor may be used topush the endoscope through the system. An attached optical sensor 4420may be used to ensure the endoscope remains in the correct positions.The spool 150 incorporates a gearbox and DC motor, which drives thespool to the correct RPM based on input from the micrometer.

In some embodiments, a DC motor may be used to control the revolutionsper minute (“RPM”) of the spool, while the fiber is fed from the furnace(not shown) through the two fiber redirection assemblies to spool. Thefiber redirector closest to the spool may be translated on a linearaxis, allowing the fiber to be translated on the spool. This enables thefiber to be laid down onto the spool properly, giving efficient and safepacking of the material.

Referring now to FIGS. 45A-45B, an exemplary spooling assembly withredirection assembly for a system for manufacturing optical fiber isillustrated.

Referring now to FIG. 45A, an exemplary view of the spooling assemblyfrom the top is shown. The linear axis (the black piece) is mounted tothe top of the box. It allows the left fiber redirection assembly tomove, which can move the fiber to different places on the spool (shownin green). It allows the left fiber redirection assembly to move, whichcan move the fiber to difference places on the spool.

Referring now to FIG. 45B, an exemplary view of the assembly from thebottom is shown. The fiber redirection assemblies are shown in red, thespool is shown in green. The spool is driven by a DC motor, the fibercan be attached to the spool by using an endoscope like device, shownlater. A linear axis may be mounted to a top of the box.

An embodiment uses a DC motor to control the RPM of the spool (shown asgreen in the picture), while the fiber is fed from the furnace (notshown) through the two fiber redirection assemblies to spool. The fiberredirector closest to the spool is translated on a linear axis, allowingthe fiber to be translated on the spool. This enables the fiber to belaid down onto the spool properly, giving efficient and safe packing ofthe material.

Referring now to FIGS. 46A-46B, exemplary assembled spools for a systemfor manufacturing optical fiber are illustrated.

Referring now to FIG. 46A, an exemplary assembled spool withoutbackplate is shown. Note the green is the surface that holds thegenerated ZBLAN fiber, while the black box is the DC motor and gearbox.

Referring now to FIG. 46B, an exemplary spool interior is shown. In someembodiments, there may be a motors housing 4615 and two bearings 4620.

Referring now to FIG. 47, a cross sectional view of an exemplary spoolfor a system for manufacturing optical fiber is illustrated. Whendirectly driven, the capstan and motor may be concentric with a plate onone end of the capstan extending to the center where it is connected tothe motor. The motor may be held fixed with structures extending out theother side of the capstan opposite of the drive shaft. The side to sideactuation is performed by linear actuators and rails mounted around thecapstan and the slides are connected to the motor structure. This spoolmay be driven by a DC motor. If the motor requires a gearbox, that canalso be placed into the interior of the spool.

Referring now to FIGS. 48A-48C, exemplary capstans with various geardesigns for a system for manufacturing optical fiber is illustrated. Insome embodiments, the gear design may comprise an asymmetric planetarygear. The gear driven design 4801 allows for compaction of the actuationcomponents and linear rail inside the capstan instead of outside it.This can help reduce the size considerably. The capstan 4810 is drivenby a planetary style gear system. This leaves room free between thegears that allow linear rails to feed through. The planetary gear caneither be symmetric with the motor centered on the axis or Asymmetricwith the motor not centered on the capstan. Either works but whenintegrating the actuator motor into the same space the Asymmetric canallow for more internal room for a given capstan diameter.

The tractor, spooling, and capstan system can be provided in a pluralityof embodiments. Different stepper motors and DC motors may be used toapply tension onto the preform material. Once combined with heat, thistension on the preform draws it into a fiber. By changing the speed ofthe DC motors and accompanying spool, the diameter of the fiber can bechanged. A fiber tractor may be used before the spool, in order to pullfiber without spooling it, while a large spool spun by motor can applythe main drawing force. By directly changing the rotation speed of thespool, the fiber diameter can be controlled, while by moving the spoolor a turning wheel in front of the spool, the fiber can be layered in aset pattern.

A tension sensor may be integrated into the redirection assembly. Thissensor, by measuring tension in the line, can help to ensure that thefiber is being drawn with the correct settings to ensure a stable pull.

Referring now to FIGS. 49A-49D, an exemplary grabbing mechanism for asystem for manufacturing optical fiber is illustrated. This mechanism isdesigned to grab onto both glass preforms and glass fiber. A DC motorfixed into a cylindrical barrel actuates a tab with a lead screw toapply the grasping force. The barrel 4910 may be mounted into a bearing4920, allowing it to rotate by a fixed secondary motor 4930. Using thisrotational degree of freedom, the same grabber 4950 may be used toeither grab a preform or a fiber. Further, this rotation allows for themechanism to guide the fiber around redirection wheels and around othermechanisms.

In an embodiment, the grabber 4950 may comprise a secondary heater,wherein a heated grabber may insert into a heated preform to initiatedraw of the fiber. In some embodiments, an electrostatic charge may beinduced at the tip of the drawn fiber, and the draw system may compriseelectrostatically driven pathway, wherein the fiber may be directedthrough the system through driving a charge through the pathway.

Referring now to FIGS. 50A-50C, an exemplary forceps control assemblyfor a system for manufacturing optical fiber is illustrated. In anembodiment, a compact assembly may extend and retract an endoscope likedevice, and mechanically control any mechanism embedded in it. Theassembly may provide autonomous control within a compact volume. Theforceps/endoscope may be wound around a spool 5010 with the mechanicalmechanisms 5020 to control any attachments at the end integrated intothe spool. By integrating them into the spool, it reduces a large amountof excess forceps/endoscope that would be wasted as a twisting bufferbetween the rotating spool and a fixed actuation mechanism. The spool isspring wound to retract the forceps. Before leaving the assembly, theforceps are routed through a motor module that uses a drive wheel/gearand pinch wheel/gear 5030 to drive the forceps/endoscopes forward andbackwards. The spring winding of the spool keeps the forceps wrappedneatly around the spool always with one end of the forceps held inposition by the motor module.

Referring now to FIG. 51, exemplary steps for pulling fiber from apreform for a system for manufacturing optical fiber are illustrated.Fiber formation is done using some form of forceps or needle 5110 tograb onto the partially melted preform to then pull the fiber throughfiber pulling assembly 5120 (usually includes redirection pulleys and anoptical micrometer) where it is attached to a spool that then pulls theremaining majority of fiber. The forceps/needle mechanism 5110 is fedthrough the fiber spool and remaining components of the assembly untilit reaches the preform in the furnace. Once there it attaches to themelting glob, retracts and forms the fiber to be pulled through theassembly and attached to fiber spool.

The current prior art method of fiber drawing involves the use of aperson for grabbing the preform drop, cutting and attaching the fiber toa spool. Embodiments disclosed herein are for the automation of thatprocess to a degree that an assembly can be supplied solely with thefiber preforms and output a fully wound spool of fiber without humaninteraction with the preform or fiber within the assembly. This has usesin the creation of small scale and entirely autonomous manufacturing offiber. Thus, embodiments may be used to create specialty fibers in theenvironment of outer space where an autonomous assembly greatly reducesthe cost compared to requiring a person to spend only a few secondsbeginning and ending a process that can then run autonomously forsignificant periods of time. Fiber formation may be done using a forcepsor needle to grab onto the partially melted preform to then pull thefiber through fiber pulling assembly (usually includes redirectionpulleys and an optical micrometer) where it is attached to a spool thatthen pulls the remaining majority of fiber. The forceps/needle mechanismis fed through the fiber spool and remaining components of the assemblyuntil it reaches the preform in the furnace. Once there it attaches tothe melting glob, retracts and forms the fiber to be pulled through theassembly and attached to fiber spool.

Referring now to FIG. 52, an exemplary alignment mechanism for pullingfiber from a preform for a system for manufacturing optical fiber isillustrated. When using forceps for gripping objects, floating in airalignment is quite important, especially when done robotically. This isa simple ring 5210 constructed of electromagnets and an optically basedmeans of determining the position of the forceps 5110. The magnets 5220are energized specifically to draw the forceps 5110 to specificpositions which would align the forceps to whatever target desiredwithout requiring a tight guide tube in that specific area. A similarring 5210 can also be constructed that uses either electrostatic forcesor small puffs of air to create the same outcome.

The prior art procedure for pulling fiber from preforms is to beginheating the preform in the middle so that the weight of the preformcauses it to neck in the molten portion. The necking leaves a stillsolid portion of preform that is then pulled from the rest and a fiberforms between them. The drop is then cut from the fiber and that fiberis then pulled. This method is reliant on the force of gravity and wouldnot work in a microgravity environment.

As disclosed herein as shown a method provides for melting a very tip ofthe preform to create a semi molten globule. The method further providesfor either grabbing by forceps or stabbing with a needle the tip of thepreform. The method further comprising pulling a fiber from the globwith the at least one of forceps and needle. The first fiber pulled canthen be used to pull the rest of the preform into fiber. This method notonly produces less waste but can be utilized in both a gravitational andnon-gravitational environment, which is important for manufacturing inspace.

Referring now to FIG. 53, an exemplary compact integrated motor andcapstan assembly for fiber spooling for a system for manufacturingoptical fiber is illustrated. The purpose of this design is to reducethe amount of unused space when driving a capstan for spooling fiber.This is of specific concern when volume is at a premium such as pullingfiber optics in space. The following are variants of the same idea forintegrating a motor within the empty space of a capstan and allowing thecapstan assembly to actuate side to side. The capstan is essentially ahollow pipe with lips on the outside and large thin form bearings on theinside to spin freely around a motor and other objects placed inside.

As shown in FIG. 53, various variations of a device that is passedthrough various path intended for the pulling of fiber. This pathincludes the preform passing through the furnace 160. This device has ahead comprising of a gripper or a spear or an interface that allows itto attach itself to either the fiber or the base material from which thefiber is formed. Once the device has attached itself it can thentransition the fiber or material through the original path for thepurpose of spooling or transitioning it to another stage of manufacture.The path may include passing by a pully and/or through a guide. Asfurther shown, there may be a starting position and an eventual endingposition.

Referring now to FIG. 54, exemplary embodiments of forceps designs for asystem for manufacturing optical fiber is illustrated. In some aspects,a device may have the added ability to encapsulate a fiber within thedevice itself. This may lead to a separate manufacturing stage, wasterecovery from miss manufacture, temporary holding during transitionstages. This ability is inherent to the device and may separate it fromthe rest of the environment in an intermittent, temporary or permanentfashion. This device may be actuated in a similar manner to linkagecables for shifting a car or activating an endoscope, there is an innersection that translates independently of the outer section. It is thisrelative motion that allows for the changing relationship to itsenvironment and grants it the ability to isolate itself. As furthershown in FIG. 54, the gripper or forceps are able to grab the fiber. Asis also shown, the gripper may have a plurality of different ends whichengage the fiber.

Thus, as shown in FIG. 54, the device, gripper or forceps, may comprisevarious inner geometries dependent of the grip type desired, such ascircular, toothed, recessed, or shaped to a specific profile. The devicemay be directly attached to an inner member that is also in the housingand is used to physically push or pull the device relative to thehousing dictation the opening and closing feature. This direct physicalmovement may be due through mechanical connection, a piston pushing afluid (e.g. water, oil, or air), or the application of a stored energyforce, releasing a compressed or stretched spring, as non-limitingexamples. This device may be used to isolate the inner housing from theenvironment, pressure/temperature carrying fluid (e.g. oil, coolant, orair) or used to contain a desired element/material from the environment.

In another embodiment, the device may be actuated with an electrical forand/or an outside mechanical force.

Referring now to FIG. 55, exemplary embodiments of forceps controldesigns for initiating fiber draw from a preform for a system formanufacturing optical fiber is illustrated. In some embodiments, adevice may be actuated open and closed in different configurations,wherein the configurations may allow it to apply varying or set amountsof force for the purpose of gripping, attaching, compressing, expandingitself to a material that can produce a fiber type material or a fiberitself. The device may be actuated by translation through a housing thatcompresses/constrains the device. The device may be energized due tothis compression the housing implements when the device is translatedthrough it. This may allow the holding action the device can give to thematerial. The device can consist of a single member/coil or many fingertype implements or coils.

In some implementations, a tube member 5510 that has a head attachmentmay attach itself to the material then pull the fiber along a specifiedpath to a spooling system. The head attachment may release the materialand the material may be spooled, or the material may be grabbed by thespooling mechanism and the fiber may then release from the tube membereither by actuating it or by breaking the fiber from the head of thetube member by using the spooling mechanism. This method may utilize thetube mechanism to perform maintenance work if the fiber breaks, becomesstuck, or to clear the system and reset it to pull fiber againminimizing down time, as non-limiting examples.

In some embodiments, a stored energy device may limit centralizationissues with regards to locating the fiber. This method may use a devicethat when it releases opens to an area that encompasses the fiber andthen is activated allowing the device to surround and close around thefiber. This may trap or grab the fiber and then the device caneffectively pull the fiber into a commercial fiber optic quality fiber.

A flowchart illustrating a method of pulling fiber optic grade materialautonomously, without manipulation that is not inherent to themanufacturing system, or without human/outside intervention may beprovided. This method comprises attaching a tube member that has a headattachment to a material to be pulled. The method also comprises pullingthe material along a specified path to a spooling system. The methodfurther comprises releasing the material as it is spooled on a spoolingmechanism.

The method may further comprise grabbing the material with the spoolingmechanism to spool the material on the spooling system. The method mayfurther comprise releasing the material from the tube member by at leastone of actuating the tube member and breaking the fiber from the head ofthe tube member by using the spooling mechanism. This method can alsoutilize the tube mechanism to perform maintenance work if the fiberbreaks, becomes stuck, etc., to clear the system and reset it to pullfiber again minimizing down time.

A method for gripping fiber utilizing a stored energy device thateliminates centralization issues with regards to locating the fiber isalso possible. This method uses a device that when releases it opens toan area that encompasses the fiber and then is activated allowing thedevice to surround and close around the fiber. This traps/grabs thefiber and then the device can effectively pull the fiber into acommercial fiber optic quality fiber.

Another method for sealing an enclosed environment from externalelements is disclosed. The method provides for a system of pressurizedchannels that will act as a barrier between an enclosed volume and theexternal environment. This system will consist of two or more sealingelements that have a void or barrier separating them. This barrier willbe pressurized with an inert gas or fluid that will isolate the internalenvironment from the external one. This helps contain the enclosedvolume as well as mitigates contamination issues the externalenvironment may cause to the internal volume. It can be used inmanufacture of materials needing ultra clean atmospheres. This may beaccomplished by directing diffusion in a specified manner from the highpressure area in between the seals to both the internal and externalenvironment. This controlled diffusion protects the clean internalenvironment from external contaminants as well as prolonging the timethe environment can remain viable as clean.

The method may also be supplemented by an internal compressor thatpressurizes the zone in between the two or more seals, creating aself-maintaining system. This method may also use a vacuum in betweenthe sealing elements. The sealing elements themselves may have externalsupport to help energize them, pressure applied to then via fluid orgas, squeeze due to the enclosure, spring type element to push againstthe seal, friction/press fit of seal in specified channel, springimbedded to seal to self-energize it, mechanical load inputted to theseal, any method of energizing the seal really. A vacuum is then pulledin between the sealing system to limit diffusion between the externaland internal environments. Any combination of the pressurized and vacuumseal concepts, with metal, mechanical, elastomeric, non-elastomericpolymer, thermoplastic, thermoset, composite, or other type of seal.

In some implementations, an enclosed environment may be sealed fromexternal elements utilizing a system of pressurized channels that mayact as a barrier between an enclosed volume and the externalenvironment. This system may consist of two or more sealing elementsthat have a void or barrier separating them. This barrier may bepressurized with an inert gas or fluid that will isolate the internalenvironment from the external one. The barrier may help contain theenclosed volume as well as mitigates contamination issues the externalenvironment may cause to the internal volume. The system may be used inmanufacture of materials needing ultra clean atmospheres, such as bydirecting diffusion in a specified manner from the high pressure area inbetween the seals to both the internal and external environment.Controlled diffusion may protect the clean internal environment fromexternal contaminants as well as prolonging the time the environment canremain viable as clean.

This method may also be supplemented by an internal compressor thatre-pressurizes the zone in between the two or more seals, creating aself-maintaining system. This method may also use a vacuum between thesealing elements. The sealing elements themselves may have externalsupport to help energize them, such as pressure applied to then viafluid or gas, squeeze due to the enclosure, spring type element to pushagainst the seal, friction/press fit of seal in specified channel,spring embedded to seal to self-energize it, mechanical load inputted tothe seal, or other methods of energizing the seal. A vacuum may pullbetween the sealing system to limit diffusion between the external andinternal environments. In some aspects, the method may utilize acombination of the pressurized and vacuum seal concepts, with metal,mechanical, elastomeric, non-elastomeric polymer, thermoplastic,thermoset, composite, or other type of seal.

FIG. 56 shows a block diagram illustrating computing functionality of aprocessing system that may be used to implement an embodiment disclosedherein. The methods provided in the embodiments disclosed above may beused in association with the computing functionality 1000 disclosedbelow to provide for real time monitoring and feedback in the depositionprocess. Multiple sensors may provide data that is used by correctionapplications provided herein with respect to the methods disclosedherein where control may be provided.

In all cases, computing functionality 1000 represents one or morephysical and tangible processing mechanisms. The computing functionality1000 may comprise volatile and non-volatile memory, such asrandom-access memory (RAM) 1002 and read only memory (“ROM”) 1004, aswell as one or more processing devices 1006 (e.g., one or more centralprocessing units (CPUs), one or more graphical processing units (Gus),and the like). The computing functionality 1000 also optionallycomprises various media devices 1008, such as a hard disk module, anoptical disk module, and so forth. The computing functionality 1000 mayperform various operations identified above when the processingdevice(s) 1006 execute(s) instructions that are maintained by memory(e.g., RAM 1002, ROM 1004, and the like).

Instructions and other information may be stored on any computerreadable medium 610, including, but not limited to, static memorystorage devices, magnetic storage devices, and optical storage devices.The term “computer readable medium” also encompasses plural storagedevices. In all cases, computer readable medium 1010 represents someform of physical and tangible entity. By way of example, and notlimitation, the computer readable medium 610 may comprise “computerstorage media” and “communications media.”

“Computer storage media” comprises volatile and non-volatile, removableand non-removable media implemented in any method or technology forstorage of information, such as computer readable instructions, datastructures, program modules, or other data. The computer storage mediamay be, for example, and not limitation, RAM 1002, ROM 1004, EPSOM,Flash memory, or other memory technology, CD-ROM, digital versatiledisks (DVD), or other optical storage, magnetic cassettes, magnetictape, magnetic disk storage, or other magnetic storage devices, or anyother medium which can be used to store the desired information andwhich can be accessed by a computer.

“Communication media” typically comprise computer readable instructions,data structures, program modules, or other data in a modulated datasignal, such as carrier wave or other transport mechanism. Thecommunication media may also comprise any information delivery media.The term “modulated data signal” means a signal that has one or more ofits characteristics set or changed in such a manner as to encodeinformation in the signal. By way of example, and not limitation,communication media comprises wired media such as a wired network ordirect-wired connection, and wireless media such as acoustic, FRO,infrared, and other wireless media. Combinations of any of the above arealso included within the scope of computer readable medium.

The computing functionality 1000 may also comprise an input/outputmodule 1012 for receiving various inputs (via input modules 1014), andfor providing various outputs (via one or more output modules). Oneparticular output module mechanism may be a presentation module 1016 andan associated graphic user interface (“GUI”) 1018. The computingfunctionality 1000 may also include one or more network interfaces 1020for exchanging data with other devices via one or more communicationconduits 1022. In some embodiments, one or more communication buses 1024communicatively couple the above-described components together.

The communication conduit(s) 1022 may be implemented in any manner(e.g., by a local area network, a wide area network (e.g., theInternet), and the like, or any combination thereof). The communicationconduit(s) 1022 may include any combination of hardwired links, wirelesslinks, routers, gateway functionality, name servers, and the like,governed by any protocol or combination of protocols.

Alternatively, or in addition, any of the functions described herein maybe performed, at least in part, by one or more hardware logiccomponents. For example, without limitation, illustrative types ofhardware logic components that may be used include Field-programmableGate Arrays (Fogs), Application-specific Integrated Circuits (Asics),Application-specific Standard Products (Asps), System-on-a-chip systems(Sacs), Complex Programmable Logic Devices (Colds), and the like.

The terms “module” and “component” as used herein generally representsoftware, firmware, hardware, or combinations thereof. In the case of asoftware implementation, the module or component represents program codethat performs specified tasks when executed on a processor. The programcode may be stored in one or more computer readable memory devices,otherwise known as non-transitory devices. The features of theembodiments described herein are platform-independent, meaning that thetechniques can be implemented on a variety of commercial computingplatforms having a variety of processors (e.g., set-top box, desktop,laptop, notebook, tablet computer, personal digital assistant (PDA),mobile telephone, smart telephone, gaming console, wearable device, anInternet-of-Things device, and the like).

Thus, as discussed above, The system is sealed to prevent anyinfiltration of humidity and filled with a dry environment. Thisenvironment could be maintained with a gas pump circulating air througha high efficiency particulate air (HEPA) filter, a carbon black filter,and molecular sieve, or other forms of environmental control, such aspumping in fresh nitrogen from the exterior.

As disclosed above, the system may be housed in a hermetically sealedbox, which may limit access to the system components. In some aspects,the seal may comprise multiple sealing mechanisms, such as anelastomeric seal between two portions of the housing and a vacuum sealbetween seal materials. For example, the system may be configured to fitinto an express rack of the International Space Station or may beself-sustaining in a free-flying spacecraft. The space limitations of anexpress rack may limit production to a single run of the preforms storedand shipped in a preform holder. For a free-flying spacecraft, thesystem may comprise mechanisms to reload, restock, or repair componentsor consumable materials. In some embodiments, the system may allow forlimited or full access to the components. For example, a portion of thehousing may be removed to allow manual access to repair, replace, orrestock components or consumable materials. As another non-limitingexample, access may be limited to restocking consumable materials, suchas preforms and spooling materials; removing deliverables, such asspools of optical fiber; and removing excess waste from a wastecollector.

The process may initiate by utilizing a large diameter preform, heatingthe preform until it is in a viscous state, then applying tension to theend of the preform. This tension may cause a section of the preform todecrease in diameter forming a “neck”. From this neck, a small fiber maybe pulled out and attached to a spool. By changing the spooling speed,the diameter of the fiber may be controlled. Coating systems may apply apolymer layer to the glass, allowing it to be bent without surfacecracks breaking. In standard gravity conditions, gravity aids theprocess by automatically allowing the neck to form, as the weight of thebottom of the preform causes the heated preform to naturally draw down.In microgravity, the effect of gravity is negligible, and the drawingprocess may be automated.

The preform containment and feed system also holds a temperature probecontaining multiple temperature sensors. This probe may be used to mapthe thermal environment of the furnace, as well simulate the heat up ofa preform. This may be particularly significant in microgravity where athermal environment may be different than in standard gravityconditions. In some embodiments, conductive heat profiles may besimulated in microgravity through use of fans.

The preform containment and feed system may be used to grip a preform,which may then be moved from the cooler ambient environment to theinterior of the furnace. The furnace may heat the preform to the correcttemperature, and the start/stop subsystem may draw fiber from the heatedpreform. This system may ensure that the preforms survive the launchprocess using several foam protective sleeves, into which the preformsare inserted during launch. Accelerometers may be attached to thepreform holder to monitor the vibrations of the preform during drawing.

The furnace is used to create the heated environment for the preform.This environment will decrease the viscosity of the preform in certainsections, allowing the preform to be drawn into fiber. The furnace iscylindrical, with an opening at the top of the furnace allowing for thepreform to be inserted and an opening at the bottom allowing for thegenerated fiber to be pulled towards the spooling system.

The furnace is used to create the heated environment for the preform.This environment will decrease the viscosity of the preform in certainsections, allowing the preform to be drawn into fiber. The furnace iscylindrical, with an opening at the top of the furnace allowing for thepreform to be inserted and an opening at the bottom allowing for thegenerated fiber to be pulled towards the spooling system.

The start/stop subsystem is the general name for starting the pullingprocess, as well as ending it. The subsystem interfaces with spoolingsubsystems extensively. The system begins the necking process of thepreform, either by poking the molten end of it, or by pulling a largesection of the bottom. Once the neck is formed, the waste can bedisposed of, and a subsystem used to draw the fiber through the entiresystem, eventually attaching the fiber to a spool. There can be severaldifferent tractors, cutting assemblies, and irises used for thisprocess.

The current design has a grabber mechanism which inserts into anattached mount on the preform. The grabber inserts into the preform oncethe preform is inserted into the hot spot, applying a constant force tosimulate 1G of gravity. The grabber then pulls the bottom chunk ofmaterial and mount back, then cut the residual off the main fiberstrand. Irises and pinch wheels then close around the fiber strand,inserting the fiber into a waste bin until it is the proper size to gothrough the rest of the system. Endoscopic forceps extend from behindthe spool, through a clamp and 2 redirection assemblies, and grab theend of a cut fiber that has been pulled from the preform. The forcepsthen draw this fiber back through the system and to the spool, where thefiber is attached. Drawing of the fiber can then commence.

In order to stop pulling, the preform feeding may stop, and the fibermay be cut or allowed to break at the neck. The spool may continue topull this loose fiber through the system, where it may be secured tospool and stored until reentry. In some aspects, debris and discardedfiber may be drawn into or placed into a waste collector.

A diameter sensor is mounted under the furnace, and is used to measurethe fiber diameter as it emerges from out of the furnace. This diametersensor is used in an active control loop to control the draw speed. Ifthe diameter is not correct, the draw speed is raised or lowered untilthe proper speed is reached to achieve nominal diameter.

The tractor, spooling, and capstan system has a large amount of designfreedom. Different stepper motors and DC motors can be used to applytension onto the preform. Once combined with heat, this tension on thepreform draws it into a fiber. By changing the speed of the DC motorsand accompanying spool, the diameter of the fiber can be changed. Afiber tractor can be used before the spool, in order to pull fiberwithout spooling it, while a large spool spun by motor can apply themain drawing force. By directly changing the rotation speed of thespool, the fiber diameter can be controlled, while by moving the spoolor a turning wheel in front of the spool, the fiber can be layered in aset pattern.

A tension sensor is integrated into the redirection assembly. Thissensor, by measuring tension in the line, can help to ensure that thefiber is being drawn with the correct settings to ensure a stable pull.In some embodiments, a portion of the electrical components may beexternal to the controlled environment. In some aspects, potted bulkheadfittings may allow for an electrical pass through with limited exposureto contaminants.

An ECU is used to maintain the environment when the pulling operation isnot occurring. This utilizes filters to eliminate particles, volatiles,and humidity from the inert gas atmosphere inside the environment. Thecurrent baseline uses a fan to suck air through a HEPA filter andactivated charcoal. This air is then pushed through molecular sieve,with baffles creating a long path for the flow through the sieve. Thus,the ambient environment can be completely clean and filter water.Temperature and pressure sensors located in the environment to ensurethat it remains in any specified or required tolerances. A humiditysensor monitors water content inside the volume.

In some aspects, a preform holder may comprise a solid-state revolverconfiguration, wherein the preform holder may rotate preforms and atleast one temperature probe. In some embodiments, the preform holder maycomprise a magazine design, wherein a new preform moves into place oncethe previous preform is discarded. In some magazine configurations, aseparate temperature probe mechanism may allow for the insertion of areusable temperature probe independent of the magazine design. In someaspects, disposable temperature probes may be integrated into themagazine, wherein the temperature probe debris may be guided into thewaste collector.

In some aspects, the waste collector may comprise a fan, which may drawair and debris into the waste collector or direct air to create abarrier to limit the loss of debris, as non-limiting examples. The wastecollector may comprise directional bristles that may limit escape ofdebris, such as in microgravity conditions. In some embodiments, thewaste collector may extend the length of the furnace, wherein preformwaste may be collected before and after the furnace. For example, afterthe furnace, the collected fiber may be trimmed of portions that do notfall into the collectible fiber parameters, and before the furnace,preform stubs may be ejected from the preform holder.

In some aspects, the waste collector may collect other unsecured debris,which may result from damage to the system or breakage of the fiberduring collection. The debris may be directed into the waste collectorthrough an integrated airflow system, which may comprise a series ofvents and ducting that may be embedded in the base or walls of thehousing. The airflow system may allow for efficient circulation of airwithin the environment and for directed airflow, such as may directfloating debris into the waste collector.

The subsystem may comprise several different embodiments for holdingmultiple preforms. One uses a solid-state revolver to hold the preformsin a circular configuration, while others utilize different magazinedesigns that use springs or motors to move preforms into position.

In some aspects, the preform may comprise a starter tip that mayfacilitate the initial fiber draw from the preform. The tip may comprisea vacuum-sealed tip, wherein a plastic grip may be attached to the endof a preform. A grabber may engage the plastic directly or may engage atip embedded in the plastic, such as a hook or loop. Once the draw isinitiated, the tip may be detached by a cutter after the furnace. Insome embodiments, the starter tip may be ground from the end of thepreform. For example, the end of the preform may comprise notches thatthe grabber may latch onto. In some aspects, preforms may bemanufactured in microgravity. For example, manufacturing preforms andthe optical fiber in low Earth orbit may allow for faster delivery ofadditional preforms.

Further, the data from any one of the sensors disclosed above may beprovided to the computing functionality 1000 to determine at leastplacement of the dispenser 142, 210 where the processor and a processorexecutable instructions are stored on the tangible storage medium toreceive a measurement from the first sensor to determine a height of thedeposition system from the build location.

Thus, as provided above, the system described herein is sealed toprevent any infiltration of humidity and filled with a dry environment.This environment could be maintained with a gas pump circulating airthrough a high efficiency particulate air (HEPA) filter, a carbon blackfilter, and molecular sieve, or other forms of environmental control,such as pumping in fresh nitrogen from the exterior.

An embodiment provides for coating the preform from which the fiber isdrawn. This method pulls the fiber and coating as one unit as the fiberis being produced. In some embodiments, ZBLAN preforms may be wrapped inheat shrink tubing. In some implementations, different materials may bewrapped using a similar process.

In some aspects, a cooling system may be integrated below the diametersensor to rapidly cool the fiber before it is coated. In an embodiment,use of air pumps or fans located perpendicular to fiber, which cool thefiber through passing air over it may be applied. Bladeless fans may beused to channel air along the fiber length. It may also be possible totouch the fiber with rolling pins, creating a conductive thermal pathwayfrom the fiber.

The coating system has several approaches. For one, it may not be neededat all, as certain grades of Teflon or other polymers can be pre-appliedand melted onto the preform. Using traditional coating methods such aspressurized dies could also provide the necessary coating when combinedwith UV curing lamps. In some aspects, using pressurized sprays ofmaterial may coat the fiber in a limited amount of space.

In some aspects, the fiber may be drawn through coating cups that maycoat the fiber in one or more coating materials and then pass throughcuring lamps. Other methods for applying coating may include capillaryaction or sonic levitation. The curing lamps may be located between thecoating cups, which may allow for wet or dry coating or wet on wetcoating, or the curing lamps may be located after the final coating cup,which may limit the coating to wet on wet. In some aspects, coatings maybe customizable, wherein the coating materials may be integrated basedon the particularly demands of a project.

In some aspects, the system may comprise a diameter sensor, which may bepositioned after the furnace. The diameter sensor may monitor thediameter of drawn fiber as it is drawn from the preform. In someembodiments, a plurality of diameter sensors may monitor diameter of thedrawn fiber throughout the manufacturing process. For example, such aswhere the furnace comprises a transparent portion, a first diametersensor may monitor the diameter of the fiber at a location proximate tothe initial draw point. A second diameter sensor may monitor thediameter the fiber as it exits the furnace. A third diameter sensor maylocated at another point in the system, wherein the third diametersensor may monitor the fiber for additional quality control.

Where a preform may be precoated, the diameter sensor may base themeasurements from surface data. For example, a micrometer may comprise alaser that may determine concentricity and diameter. Without thecoating, the fiber may be transparent, and the diameter sensor mayutilize surface data and internal data, such as to monitor clarity ofthe fiber.

In some embodiments, the system may comprise tension sensors, which maybe monitor tension of the fiber being pulled by the forceps. A suddenloss in tension may indicate a break, and a building increase in tensionmay precede a break. The monitored data may prompt an action by a systemcomponent. For example, a break may stop the fiber draw and prompt achange to the next preform. A break may also prompt fans to direct anyfloating debris to the waste collector.

In some aspects, some sensors may be active during transportation of thesystem, wherein the active sensors may monitor conditions for thresholdlevels, which may adversely affect the system. Accelerometers may beactive during a launch to monitor threshold vibration levels that maycause damage to the system, such as damaging the preforms or causing thesubsystem to fall out of alignment with the furnace or spool, asnon-limiting examples. In some aspects, environmental sensors may beperiodically activated to ensure the conditions stay within predefinedparameters.

For example, temperature and humidity sensors may activate every tendays while the system is stored in an open warehouse. The data may betransmitted when the sensors are activated or the data may be accessedat logistic checkpoints. For example, the humidity data may be accessedprior to launch, wherein there may be an opportunity to retreat thesystem, such as flushing the environment with nitrogen. Accessing sensordata prior to installation or launch may limit installation or launch ofdamaged systems.

In some implementations, the system may comprise a gantry system, whichmay allow for more precise manipulation of components within the system.The system may comprise sensors that may monitor for damage to acomponent or the housing. A repair arm on the gantry system may beequipped to repair holes or cuts. For example, it may add an epoxy ormonomer then apply a curing mechanism, such as exposure to UV or heat.As another example, the arm may weld small holes. In some aspects, thesystem may comprise a contamination sensor, and the repair arm mayexpose the section to UV to kill living contaminants.

In some aspects, the spooling mechanism may comprise an internal motor,wherein the spool may spin around the motor. In some embodiments, thespool portion may be removable and replaceable. For example, once full,the spool portion may be removed and transported in that spool. In someimplementations, the fiber may be transferred to a secondary spool,which may be less expensive or more efficient.

Where the spool may be replaceable, the system may be shipped orlaunched with a batch of spools. For example, where the system isaccessible, the spools may be replaced manually or through automation.In some aspects, full spools may be removed and stored for shipmentwithin the system, such as in a free-flying spacecraft. Where spools maybe stored and/or shipped separately, they may be collapsible or able tobe assembled. A spool may comprise three flat pieces that connect or fitinto each other to form the spool. In some aspects, the spool may beprinted onsite, which may allow for local manufacturing of the spools ondemand.

The spool may comprise a catching mechanism that may secure a fiber endto the spool. In some aspects, the catching mechanism may comprise agrip that may be magnetically or spring-driven. For example, the gripmay be triggered once a predefined amount fiber is in contact with thespool. As another example, the grip may be triggered based on apredefined amount of pressure applied by one or both the forceps and thefiber. A still further example, the grip may be triggered by a controlmechanism.

In some aspects, the surface of the spool may comprise a passivegripping material or surface. Optical fiber may be delicate,particularly during the initial spooling stage, which may wrap at thelow diameter, and catching methods may account for this fragility. Forexample, the spool may comprise a friction lock or a v-catch that mayengage the fiber as it is spooled. As another example, the surface ofthe spool may comprise a sticky material, such as a soft rubber, waxpaper, epoxy, or tape. The sticky material may be inherent to the spoolsurface or may be applied when the fiber is spooled. For example, apiece of double-sided tape may be adhered to the portion of the spoolthat the fiber may wind around. The pieces of tape may be precut or cutfrom a tape-dispensing unit. Where the system may be intended forextended use with restockable materials, tape embodiments may bepractical and easily and inexpensively restocked.

Temperature and pressure sensors are located in the environment toensure that it remains in the specified tolerances as required any spacelaunch agency or company, such as, but not limited to NASA. A humiditysensor monitors water content inside the volume. Finally, accelerometerscan be attached to the preform holder to monitor the vibrations of thepreform during drawing.

An alternate option is to coat the preform from which the fiber isdrawn. This method pulls the fiber and coating as one unit as the fiberis being produced. In some embodiments, ZBLAN preforms may be wrapped inheat shrink tubing. In some implementations, different materials may bewrapped using a similar process.

In some aspects, a cooling system may be integrated below the diametersensor to rapidly cool the fiber before it is coated. Current designsuse air pumps or fans located perpendicular to fiber, which cool thefiber through passing air over it. Bladeless fans may be used to channelair along the fiber length. It may also be possible to touch the fiberwith rolling pins, creating a conductive thermal pathway from the fiber.

The coating system has several approaches. For one, it may not be neededat all, as certain grades of Teflon or other polymers can be preappliedand melted onto the preform. Using traditional coating methods such aspressurized dies could also provide the necessary coating when combinedwith UV curing lamps. In some aspects, using pressurized sprays ofmaterial may coat the fiber in a limited amount of space.

In some aspects, the fiber may be drawn through coating cups that maycoat the fiber in one or more coating materials and then pass throughcuring lamps. Other methods for applying coating may include capillaryaction or sonic levitation. The curing lamps may be located between thecoating cups, which may allow for wet on dry coating or wet on wetcoating, or the curing lamps may be located after the final coating cup,which may limit the coating to wet on wet. In some aspects, coatings maybe customizable, wherein the coating materials may be integrated basedon the particularly demands of a project.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting. As used herein, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise.Furthermore, to the extent that the terms “including,” “includes,”“having,” “has,” “with,” or variants thereof are used in either thedetailed description and/or the claims, such terms are intended to beinclusive in a manner similar to the term “comprising.” Moreover, unlessspecifically stated, any use of the terms first, second, etc., does notdenote any order or importance, but rather the terms first, second,etc., are used to distinguish one element from another.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which embodiments of the inventionbelongs. It will be further understood that terms, such as those definedin commonly used dictionaries, should be interpreted as having a meaningthat is consistent with their meaning in the context of the relevant artand will not be interpreted in an idealized or overly formal senseunless expressly so defined herein.

While various disclosed embodiments have been described above, it shouldbe understood that they have been presented by way of example only, andnot limitation. Numerous changes, omissions and/or additions to thesubject matter disclosed herein can be made in accordance with theembodiments disclosed herein without departing from the spirit or scopeof the embodiments. Also, equivalents may be substituted for elementsthereof without departing from the spirit and scope of the embodiments.In addition, while a particular feature may have been disclosed withrespect to only one of several implementations, such feature may becombined with one or more other features of the other implementations asmay be desired and advantageous for any given or particular application.Furthermore, many modifications may be made to adapt a particularsituation or material to the teachings of the embodiments withoutdeparting from the scope thereof.

Further, the purpose of the foregoing Abstract is to enable the U.S.Patent and Trademark Office and the public generally and especially thescientists, engineers and practitioners in the relevant art(s) who arenot familiar with patent or legal terms or phraseology, to determinequickly from a cursory inspection the nature and essence of thistechnical disclosure. The Abstract is not intended to be limiting as tothe scope of the present disclosure in any way.

Therefore, the breadth and scope of the subject matter provided hereinshould not be limited by any of the above explicitly describedembodiments. Rather, the scope of the embodiments should be defined inaccordance with the following claims and their equivalents.

1. A preform storage system for using a system for drawing opticalfiber, the system comprising: a magazine device which receives a nextpreform material once a prior perform material is discarded; atemperature probe mechanism to measure temperature at the magazinedevice; and a waste collector.
 2. A preform material, the preformmaterial comprising a starter tip to facilitate an initial fiber drawfrom the preform within a furnace, wherein the tip comprises avacuum-sealed tip to receive a plastic grip which attached to an end ofa preform.